Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
  • E04F15/107—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials composed of several layers, e.g. sandwich panels
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
  • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
  • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
  • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
  • B32B27/322—Layered products comprising a layer of synthetic resin comprising polyolefins comprising halogenated polyolefins, e.g. PTFE
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B27/00—Layered products comprising a layer of synthetic resin
  • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
  • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
  • B32B3/06—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions for securing layers together; for attaching the product to another member, e.g. to a support, or to another product, e.g. groove/tongue, interlocking
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B38/00—Ancillary operations in connection with laminating processes
  • B32B38/10—Removing layers, or parts of layers, mechanically or chemically
  • B32B38/105—Removing layers, or parts of layers, mechanically or chemically on edges
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/02038—Flooring or floor layers composed of a number of similar elements characterised by tongue and groove connections between neighbouring flooring elements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F15/00—Flooring
  • E04F15/02—Flooring or floor layers composed of a number of similar elements
  • E04F15/10—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials
  • E04F15/105—Flooring or floor layers composed of a number of similar elements of other materials, e.g. fibrous or chipped materials, organic plastics, magnesite tiles, hardboard, or with a top layer of other materials of organic plastics with or without reinforcements or filling materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/02—Synthetic macromolecular particles
  • B32B2264/0214—Particles made of materials belonging to B32B27/00
  • B32B2264/0228—Vinyl resin particles, e.g. polyvinyl acetate, polyvinyl alcohol polymers or ethylene-vinyl acetate copolymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
  • B32B2264/02—Synthetic macromolecular particles
  • B32B2264/0214—Particles made of materials belonging to B32B27/00
  • B32B2264/025—Acrylic resin particles, e.g. polymethyl methacrylate or ethylene-acrylate copolymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2270/00—Resin or rubber layer containing a blend of at least two different polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/554—Wear resistance
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
  • B32B2307/558—Impact strength, toughness
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2307/00—Properties of the layers or laminate
  • B32B2307/70—Other properties
  • B32B2307/732—Dimensional properties
  • B32B2307/734—Dimensional stability
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2419/00—Buildings or parts thereof
  • B32B2419/04—Tiles for floors or walls
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B2471/00—Floor coverings
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/01—Joining sheets, plates or panels with edges in abutting relationship
  • E04F2201/0153—Joining sheets, plates or panels with edges in abutting relationship by rotating the sheets, plates or panels around an axis which is parallel to the abutting edges, possibly combined with a sliding movement
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
  • E04F2201/00—Joining sheets or plates or panels
  • E04F2201/02—Non-undercut connections, e.g. tongue and groove connections
  • E04F2201/023—Non-undercut connections, e.g. tongue and groove connections with a continuous tongue or groove

Definitions

• Polymeric flooring systems comprise a plurality of flooring panels that are installed adjacent to one another.
• flooring panels having a flush side edge geometry allowed for tight seams between adjacent flooring panels.
• flush edge geometry tends to allow for relative movement between each flooring panel in the fully installed state when mechanical stress is applied to the flooring system (i.e. walking on the flooring panels).
• mechanical locking profiles have been formed in the side edge surfaces of these flooring panels, thereby improving the overall stability of resulting flooring system.
• mechanical locking profiles provide a first flooring panel having a first edge geometry (e.g. a tongue) and a second flooring panel having a second edge geometry that somewhat occupies the negative space of the first edge geometry (e.g., a groove).
• first edge geometry e.g. a tongue
• second edge geometry accepts the first edge geometry (or vice versa) causing the first and second flooring panels to interlock.
• the mechanical locking profiles add to the overall cosmetic appearance of the flooring system by maintaining tight seams between the first and second edges of adjacent flooring panels.
• the present invention is directed to a flooring panel comprising a substrate layer and a wear layer atop the substrate layer.
• the wear layer may comprise a vinyl polymer and an impact modifier.
• the wear layer may also be substantially free of plasticizer.
• the present invention is directed to a method of forming a flooring panel, tile or sheet.
• the present flooring products are referred to as a flooring panel.
• the method may first comprise a step of forming a laminate structure comprising a substrate and a wear layer atop the substrate.
• the wear layer may comprise a vinyl polymer and an impact modifier, and the wear layer may be substantially free of plasticizer.
• the method may further comprise a step of machining a first edge of the laminate structure to form a first mechanical locking profile, and a second edge of the laminate structure to form a second mechanical locking profile, thereby forming the flooring panel.
• the wear layer may form a first portion of each of the first and second mechanical locking profiles.
• the substrate layer may form a second portion of each of the first and second mechanical locking profiles.
• Figure 1 is a perspective view of a flooring panel according to some embodiments of the present invention.
• Figure 2 is a side profile view of a laminate structure according to some embodiments of the present invention.
• Figure 3 is a side profile view of a flooring panel according to some embodiments of the present invention.
• the term “about” means +/- 5%.
• the phrase “substantially free” means less than 4 wt. % based on the total weight of the referenced composition.
• the present invention is directed to a flooring panel 10 comprising a wear layer 30 and a substrate layer 20, the wear layer 30 atop the substrate layer 20.
• the wear layer 30 of the present invention may comprise a polymer and one or more additives.
• the polymer is selected from thermoplastic polymer.
• the additives may include impact modifier, filler, pigment, lubricant, stabilizer, and a combination of two or more thereof.
• a wear layer is produced by an extrusion or calendaring process.
• the polymer may include a vinyl polymer, copolymers thereof, and mixtures of two or more thereof.
• Non-limiting examples of the vinyl polymer suitable for the wear layer include chlorinated vinyl polymers, such as polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), and copolymers of vinyl chloride and alkene monomer - such as a copolymer of vinyl chloride and vinyl acetate, as well as mixtures thereof.
• the wear layer 30 of the present invention is substantially free of plasticizer. Without plasticizer, the resulting wear layer 30 exhibits greater dimensional stability over time with exposure to heat and moisture.
• the wear layer 30 comprises less than 0.05 wt. % of plasticizer based on the total weight of the wear layer 30. In a preferred embodiment, the wear layer 30 is entirely free (0 wt.
• plasticizer based on the total weight of the wear layer 30.
• plasticizer may include low molecular weight phthalate esters.
• wear layer 30 that is produced substantially free of plasticizer is not formed from plastisol, as plastisol is a mixture of vinyl polymer resin and plasticizer.
• an impact modifier may be present in the wear layer in an amount ranging from 3 wt. % to about 15 wt. % - including all integers and sub-ranges there-between based on the total weight of the wear layer composition.
• the impact modifier is present in an amount ranging from about 4 wt. % to about 10 wt. % - including all integers and sub-ranges there-between.
• the polymer and the impact modifier may be present in a weight ratio ranging from about 20: 1 to about 7: 1 - including all sub-ranges there-between. In a preferred embodiment, the polymer and impact modifier are present in a weight ratio ranging from about 20: 1 to about 16: 1.
• the wear layer 30 may contain a polymer, an impact modifier, a processing aid, a lubricant and a stabilizer.
• An exemplary wear layer composition may contain a polymer, e.g., PVC, and an impact modifier, e.g., acrylic impact modifier.
• a suitable processing aid that improves the processability of a chlorinated polymer, improving such properties as flowability, melt fusability, and surface appearance includes acrylic polymer processing aids.
• a suitable processing aid includes PARALOIDTM K-120ND, available from Dow Chemical.
• Lubricants suitable for the invention include acrylic polymer lubricants, such as, PARALOIDTM K-175, available from Dow Chemical; fatty acid lubricants, such as stearate metal salt lubricants, e.g., SynproTM calcium stearate 114, available from Ferror; and combinations thereof.
• An exemplary wear layer composition may contain polyvinyl chloride, an acrylic impact modifier between 2 and 20 PHR (parts per hundred parts of polymer resin, PVC), an acrylic processing aid between 0.1 and 5 PHR, an acrylic lubricant between 0.1 and 5 PHR, a stearate metal salt lubricant between 0.1 and 5 PHR, and a calcium- zinc stabilizer between 0.1 and 5 PHR.
• a preferred wear layer composition may contain polyvinyl chloride, an acrylic impact modifier between 5 and 15 PHR (parts per hundred parts of polymer resin, PVC), an acrylic processing aid between 0.5 and 2 PHR, an acrylic lubricant between 0.5 and 2 PHR, a stearate metal salt lubricant between 0.5 and 2 PHR, and a calcium-zinc stabilizer between 0.5 and 2 PHR.
• Suitable impact modifiers for the present invention include acrylic impact modifiers (ACR), chlorinated polyethylene (CPE), methyl methacrylate-butadiene-styrene copolymers (MBS), copolyamides, styrene-butadiene- styrene copolymers (SBS), acrylonitrile-butadiene- styrene copolymer (ABS), and a combination thereof.
• Suitable acrylic impact modifiers include ACRs with a core-shell structure having a crosslinked butyl acrylate core and a grafted methyl methacrylate shell.
• Suitable chlorinated polyethylene includes a high molecular copolymer of high density polyethylene and chlorine.
• Suitable methyl-methacrylate, butadiene and styrene copolymers include core-shell copolymer having a butadiene-styrene core and a grafted methyl methacrylate shell.
• Suitable copolyamides include random copolymers of polyamides including copolyamides based on caprolactam, laurolactam, amino undecyclic acid, and polyethylene glycol, which is typically used as hot melt adhesives.
• suitable material includes, for example, HI 937 Platamid® available commercially from Arkema. Of these, preferred are acrylic impact modifiers since acrylic impact modifiers are less susceptible to oxidative degradation.
• the SBS comprises styrene and butadiene in a weight ratio of about 28:72 to about 48:52. In some embodiments, the SBS comprises styrene and butadiene in a weight ratio of about 30:70 to about 40:60. In some embodiments, the SBS comprises about a ratio of about 30:70 of styrene : butadiene. In some embodiments, the ABS comprises 40 wt. % to 50 wt. % of styrene, 25 wt. % to 30 wt. % of butadiene, and 25 wt. % to 30 wt. % of acrylonitrile. In some embodiments, the impact modifier is substantially free of methyl- methacrylate-butadiene-styrene (MB S ) .
• M S methyl- methacrylate-butadiene-styrene
• the core comprise polybutyl acrylic polymer and the shell may comprise polymethyl-methacrylate.
• the polymeric core may have a glass transition (Tg) that is lower than the Tg of the polymeric shell.
• Tg glass transition
• the polymeric core may have a Tg ranging from about -50 °C to about 60 °C.
• the Tg of the polymeric core may range from about -20 °C to about 20 °C.
• the polymeric shell may have a Tg ranging from about 50 °C to about 110 °C.
• the polymeric shell may have a Tg that is lower than the Tg of the polymeric core.
• the polymeric core may have a Tg ranging from about 50 °C to about 110 °C.
• the polymeric shell may have a Tg ranging from about -50 °C to about 60 °C.
• the Tg of the polymeric shell may range from about -20 °C to about 20 °C.
• the core-shell polymer particles have an average particle size ranging from about 50 nanometers (nm) to about 5,000 nm - including all sub-ranges and values there between. In one embodiment, the core-shell polymer particles have an average particle size ranging from about 50 nm to about 1,000 nm. In a non- limiting embodiment, the core- shell polymer particles have an average particle size ranging from about 100 nm to about 200 nm.
• the wear layer preferably has a Tensile Energy Absorption (TEA) value greater than about 4.5 Joules/cm , at least (or greater than) about 4.6 Joules/cm 2 , at least (or greater than) about 4.7 Joules/cm 2 , at least (or greater than) about 4.8 Joules/cm 2 , at least (or greater than) about 4.9 Joules/cm 2 , preferably at least (or greater than) about 5 Joules/cm .
• TSA Tensile Energy Absorption
• the wear layer may have a TEA ranging from about 4.5 Joules/cm 2 to about 6.0 Joules/cm 2 - including all sub-ranges and values by a 0.1 Joules/cm increment there-between.
• TEA is a measure of the ability of a film to absorb mechanical shocks. TEA can easily be determined by analyzing the relationship between stress and strain in the tensile test ASTM D828-97 (reapproved 2002). The area under the stress-strain curve can be mathematically derived, and then factored into an equation as given in the test method to yield tensile energy absorption (TEA). The higher the TEA in a film, the easier it is to stress the film without it fracturing. It has been found that lower than a desired TEA value leads to chipping when a flooring panel with the wear layer is subjected to machining to profile the locking system.
• the flooring panel 10 may further comprise a top panel surface 11 and a bottom panel surface 12 that is opposite the top panel surface 11.
• the top panel surface 11 is formed by the wear layer 30.
• the bottom panel surface 12 is formed by the substrate layer 20.
• the top panel surface 11 is formed by a top coat 40 applied atop the wear layer 30.
• the bottom panel surface 12 is formed by an underlayment 50 beneath the substrate layer 20.
• the flooring panel 10 may further comprise a plurality of panel edges 13 that extend between the top panel surface 11 and the bottom panel surface 12 of the flooring panel 10.
• the plurality of panel edges 13 defines a perimeter of the flooring panel 10.
• the panel edges 13 comprise a first panel edge 13a and a second panel edge 13b opposite the first panel edge 13a.
• the wear layer 30 may form a first portion of each of the first panel edge 13a and the second panel edge 13b.
• the substrate layer 20 may form a second portion of each of the first panel edge 13a and the second panel edge 13b.
• the first panel edge 13a comprises a first mechanical locking profile 100.
• the second panel edge 13b comprises a second mechanical locking profile 200.
• the first mechanical locking profile 100 may be configured to accept the second mechanical locking profile 200.
• the wear layer 30 may form a portion of each of the first mechanical locking profile 100 and the second mechanical locking profile 200.
• the first mechanical locking profile 100 may comprise a first horizontal locking feature 110 - which may be in the form of a recess.
• the first mechanical locking profile 100 may comprise a first vertical locking feature 120 - which may be in the form of a flange.
• the second mechanical locking profile 200 may comprise a second horizontal locking feature 210, which may be in the form of a lip.
• the second mechanical locking profile 200 may comprise a second vertical locking feature 220, which may be in the form of a flange.
• the first horizontal locking feature 110 may be configured to cooperate with the second horizontal locking feature 210 to provide horizontal locking between adjacent flooring panels 10.
• the first vertical locking feature 120 may be configured to cooperate with the second vertical locking feature 220 to provide horizontal locking between adjacent flooring panels 10.
• the first horizontal locking feature 110 comprises a first horizontal locking wall 111 and a second horizontal locking wall 112 that faces the first horizontal locking wall 111.
• the first vertical locking feature 120 comprises a first vertical locking surface 121 and a second vertical locking surface 122 that is opposite the first vertical locking surface 121.
• the first vertical locking feature may further comprise a first distal surface 123 that extends from the first vertical locking surface 121 to the second vertical locking surface 122 in a direct that is either oblique to or at a right angle to at least one of the first or second vertical locking surfaces 121, 122.
• the first vertical locking surface 121 may face substantially the same direction as the top panel surface 11 of the flooring panel 10.
• the second vertical locking surface 122 may face substantially the same direction as the bottom panel surface 12 of the flooring panel 10.
• the substrate layer 20 may form the first horizontal locking wall 111 and the second horizontal locking wall 112 of the first horizontal locking feature 110. According to some embodiments of the present invention, the substrate layer 20 may form the first vertical locking surface 121, the second vertical locking surface 122, and the first distal surface 123 of the first vertical locking feature 120.
• the second horizontal locking feature 210 comprises a third horizontal locking wall 211 and a fourth horizontal locking wall 212 that is opposite the third horizontal locking wall 211.
• the second vertical locking feature 220 comprises a third vertical locking surface 221 and a fourth vertical locking surface 222.
• the third vertical locking surface 221 faces substantially the same direction as the bottom panel surface 12 of the flooring panel 10.
• the fourth vertical locking surface 222 faces substantially the same direction as the top panel surface 11 of the flooring panel 10.
• the substrate layer 20 may form the third horizontal locking wall 211 and the fourth horizontal locking wall 212 of the second horizontal locking feature 210. According to some embodiments of the present invention, the substrate layer 20 may form the third vertical locking surface 221, the fourth vertical locking surface 222 of the second vertical locking feature 220.
• a flooring system may be installed by positioning a first flooring panel and a second flooring panel adjacent to each other and locking the first mechanical locking profile 100 of the first flooring panel with the second mechanical locking profile 200 of the second flooring panel.
• the first horizontal locking wall 111 of the first flooring panel 10 may be immediately adjacent to, preferably abutting, the third horizontal locking wall 211 of the second flooring panel 10.
• the first vertical locking surface 121 of the first flooring panel 10 may be immediately adjacent to, preferably abutting, the third vertical locking surface 221 of the second flooring panel 10.
• each of the first panel edge 13a and the second panel edge 13b comprises an upper portion 300 that is adjacent to the top panel surface 11 of the flooring panel 10.
• the upper portion 300 of the first panel edge 13a may comprise a first recess 130.
• the first recess 130 may comprise a recess wall surface 131 that extends from the top panel surface 11 toward the bottom panel surface 13 in a direction that is either oblique or at a right angle to the top panel surface 11.
• the first recess 130 may further comprise a recess floor surface 132 that extends from the recess wall surface 131 toward the first distal surface 123 of the first vertical locking feature 120.
• the recess floor surface 131 may be coplanar with the first vertical locking surface 121 of the first vertical locking feature 120. In some embodiments, the recess floor surface 132 may extend outward from the recess wall surface 131 in a direction that is substantially parallel to at least one of the top panel surface 11 and the bottom panel surface 12.
• the wear layer 30 forms a portion of the recess wall surface 131 of the first recess 130.
• the substrate layer 20 forms a portion of the recess wall surface 131 of the first recess 130.
• the substrate layer 20 forms the recess floor surface 132 of the first recess 130.
• a top coat 40 forms a portion of the recess wall surface 131.
• the upper portion of the second panel edge 13b comprises a first flange 140.
• the first flange 140 may comprise a distal surface 141.
• the distal surface 141 of the first flange 140 may extend from the top panel surface 11 toward the bottom panel surface 13 in a direction that is either oblique or at a right angle to the top panel surface 11.
• the distal surface 141 of the first flange 140 may extend from the top panel surface 11 to the third vertical locking 221 of the second vertical locking feature 220.
• the wear layer 30 forms a portion of the distal surface 141 of the first flange 140.
• the substrate layer 20 forms a portion of the distal surface 141 of the first flange 140.
• a top coat layer 40 forms a portion of the distal surface 141 of the first flange 140.
• the flooring panel 10 having the first mechanical locking profile 100 and the second mechanical locking profile 200 may be formed by first creating a laminate structure 60, as shown in Figure 2.
• the laminate structure 60 may be formed by coupling the wear layer 30 and the substrate layer 20 together - the wear layer 30 being atop the substrate layer 20.
• the laminate structure 60 may further comprise one or more additional layers, as described herein.
• the laminate structure 60 may comprise a top laminate surface 61, a bottom laminate surface 62, and a plurality of laminate edges 63 that extend between the top and bottom laminate surfaces 61, 62.
• the laminate edges 63 may comprise a first laminate edge 63a and a second laminate edge 63b that is opposite the first laminate edge 63a.
• the wear layer 30 forms a first portion of each of the first laminate edge 63a and the second laminate edge 63b.
• the first and second laminate edges 63a, 63b are then machined by a suitable blade from a machining apparatus.
• a non-limiting example of a machining apparatus is a router comprising a rotating router blade.
• machining the first laminate edge 63a with the suitable blade forms the first mechanical locking profile 100 of the first panel edge 13a - such that the wear layer 30 forms a first portion of the first mechanical locking profile 100 and the substrate layer 20 form a second portion of the first mechanical locking profile 100.
• machining the second laminate edge 63b with the suitable blade forms the second mechanical locking profile 200 of the second panel edge 13b - such that the wear layer 30 forms a first portion 300 of the second mechanical locking profile 200 and the substrate layer 20 form a second portion 400 of the second mechanical locking profile 200.
• the wear layer 30 is removed by the blade during machining.
• Using the wear layer 30 formulation of the present invention provides first and second panel edges 13a, 13b - including the first and second mechanical locking profiles 100, 200 - that are substantially free of chips and have a smooth surface texture.
• the wear layer 30 may have a thickness ranging from about 3 to about 40 mil, preferably from about 5 to about 20 mil - including all integers and sub-ranges there-between.
• the substrate layer 30 of the flooring panel 10 may have an overall thickness ranging from about 60 to about 200 mil - including all integers and sub-ranges therebetween.
• the substrate layer 20 may be comprised of a single core layer comprised of binder and filler (not pictured). Such single core layer have a thickness ranging from 50 to 150 mil.
• the substrate layer 20 is comprised of multiple core layers - including at least an upper core layer 21 and a lower core layer 22, the upper core layer 21 being atop the lower core layer 22.
• the upper core layer 21 comprises a first amount of binder and filler and the lower core layer 22 comprises a second amount of binder and filler, wherein the first amount of binder and filler is either the same or different than the second amount of binder and filler. In a preferred embodiment, the first amount of binder and filler is different than the second amount of binder and filler.
• the upper core layer 21 may have a thickness ranging from about 30 to about 100 - including all integers and sub-ranges there-between.
• the lower core layer 22 may have a thickness ranging from about 30 to about 100 - including all integers and sub-ranges there-between.
• an intermediate core layer 23 may be positioned between the upper core layer 21 to the lower core layer 22.
• the intermediate core layer 22 may be an adhesive, a thermal and/or acoustical insulating material, or a combination thereof.
• the binder of the core layers may comprise addition polymers, such as acrylic polymers and vinyl polymers, condensation polymers, or a combination of two or more thereof.
• vinyl polymer include polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), copolymers of vinyl chloride and alkene monomer, as well as mixtures thereof.
• PVDC polyvinylidene chloride
• condensation polymers include polyester, polyamide, and polyurethane.
• the filler may include particles of calcium carbonate, talc, alumina, cellulosic material, and combinations of two or more thereof.
• the substrate layer may be the polymeric core, which comprises a binder polymer and a filler of a Luxury Vinyl Tile ("LVT”), a Vinyl Composition Floor Tile (“VCT”), and a Solid Vinyl Floor Tile (“SVT”).
• suitable substrates that can be used with the wear layer include plastic composite cores and wood plastic composite cores.
• "luxury vinyl tile” is an understood term of art in the flooring industry.
• "Vinyl Composition Floor Tile” (VCT) is an accepted official standard category for flooring materials within the flooring industry.
• SVT Solid Vinyl Floor Tile
• the flooring panel 10 may further comprise an underlayment layer 50 beneath the substrate layer 20. In some embodiments, the flooring panel 10 may further comprise a top coat 40 atop the wear layer 30. Some embodiments provide that one or more intervening located between the wear layer 30 and the top coat 40. A non-limiting example of such intervening layers include one or more decorative print layers. Some embodiments provide that one or more additional layers can be positioned between the wear layer 30 and the substrate layer 20.
• the top coat 40 may comprise one of the aforementioned vinyl polymers, polyurethane, or polyester, and fillers and additives.
• the fillers may comprise abrasive particles, such as alumina, diamond, carbide or silica.
• the top coat 40 is a clear coat having about 100% transparency.
• the top coat 40 may have a thickness ranging from about 0.25 to about 1.5 mil - including all integers and sub-ranges there-between.
• the underlayment layer 50 may comprise an insulating material, such as cork, PVC, polyurethane, or polyolefin, which may be foamed or solid.
• the underlayment layer 50 may have a thickness ranging from about 5 to about 100 mil - including all integers and sub-ranges there-between.
• the following examples are prepared in accordance with some embodiments of the present invention.
• the examples are prepared by dry blending the ingredients in a dry blender creating a dry mix. Mixing mill rolls are pre-heated to 350 °F and the dry mix is slowly added to the nip of the mill roll. The dry mix is continually added until a clear film / sheet is developed on the mill roll at which point the sheet is pulled from the mill roll and cooled to room temperature. Each sheet is then tested for tensile energy absorption (TEA) using an Instron tensile strength testing machine.
• TSA tensile energy absorption
• PVC polyvinyl chloride polymer
• IM-1 o Impact Modifier 1
• IM-2 o Impact Modifier 2
• IM-3 o Impact Modifier 3
• IM-4 o Impact Modifier 4
• Ecoflex F Blend C1200 52 wt.% of polyesters similar to the polyester indicated above as IM-3;
• Lubricant - acrylic composition commercially available from Dow as Paraloid K-175
• o L-2 Lubricant - calcium stearate, commercially available from Ferro as Synpro Calcium Stearate 114-40
• Veg o S Stabilizer (S) - Calcium Zinc, commercially available from Baerlocher as Baerostrab B2389.
• a flooring sample is produced thermally laminating a conventional LVT substrate and the commercial impact modified film CS 1.
• the flooring sample is machined to provide a locking system.
• the machining of the flooring sample results in chipping of the CS 1 layer.
• polyesters are added in the wear layer composition with the expectation that resilient polymer may provide improved tensile strength.
• Ex. 5 demonstrates that, as expected, the addition of a high content of processing aids reduces the tensile properties of the wear layer.
• Each sample is tested for resistance to yellowing by exposing each test sample to light for a period of time to simulate exposure to sunlight over an extended period of time. A visual assessment is then performed to see if yellowing had occurred in each sample. The results are provided below in Table 2.
• the wear layer containing a plasticizer e.g., phthalate plasticizer or nonphthalate plasticizer, such as cyclohexane dicarboxylic acid diisononyl ester, which plasticizer may migrate out to the wear layer surface and require a thermal annealing process to stabilize the layer.
• a plasticizer e.g., phthalate plasticizer or nonphthalate plasticizer, such as cyclohexane dicarboxylic acid diisononyl ester

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• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Mechanical Engineering (AREA)
• Floor Finish (AREA)
• Laminated Bodies (AREA)

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• 2015
  • 2015-08-12 US US14/824,261 patent/US20170044778A1/en not_active Abandoned
• 2016
  • 2016-07-13 CN CN201680042172.2A patent/CN107849851A/zh active Pending
  • 2016-07-13 WO PCT/US2016/041959 patent/WO2017027155A1/en active Application Filing
  • 2016-07-13 EP EP16835591.5A patent/EP3332075A4/de not_active Withdrawn
  • 2016-07-13 AU AU2016304693A patent/AU2016304693A1/en not_active Abandoned
  • 2016-07-19 TW TW105122734A patent/TW201712195A/zh unknown
• 2022
  • 2022-01-12 AU AU2022200159A patent/AU2022200159A1/en not_active Abandoned

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